Composite box and manufacture thereof



Jan. 11, 1938. F. R. NEELY 2,105,359

COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. 15, 1931 16 Sheets-Sheet 2 Jan. Il, 1938. F. R. NEELY w COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. 15, 1931 16 Sheets-Sheet 5 Jan. l1, 1938. F R NEELY 2,105,359

COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet 4 `an. l1, 1938. F. R. NEELY 2,105,359

COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. 15, 1951 le'sheets-sheet 5 Jan. l1, 1938. F, R, NEELY v 2,105,359

COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet 6 wig 16 Sheets-Sheet 7 F. R. NEELY Filed Aug. l5, 1931 Ime/l?? Jan. 11, 1938.

COMPOSITE BOX AND MANUFACTURE THEREOF Jan. 11, 1938. F. R. NEELY COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet 8 `Fan. ll, 1938.

F. R. NEELY 2,105,359

COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 SheetS-Sheeb 9 Jan. il, 1938. F. R. NEELY COMPOSITE BOX, AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet l0 Jan. 11, 1938. F. R. NEELY 2,105,359

COMPOSITE BOX AND MANUFACTURE THE'REOF I Filed Aug.. 151951 1e sheets-sheet 11 Jan. l1, 1938. F. R. NEELY coMPQsIT`Box AND MANUACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet 12 Y F- R NEELY l I {fl .Jllll '1)1, [im e 1s 5, l H |y 'IH ,II 1 I f l Vl l 1" ,N f l l t 57 I l f. Il V- 1 j I l ,l 'y f/f r IlI jg A f 66 Hw :l .by l

Jan. ll, 1938. F. R. NEELY COMPOSITE BOX AND MANUFACTURE THEREOF 16 Sheets-Shea?l 14 Filed Aug. l5, 1931 Jan. 11, 1938.

F. R. NEELY COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet 15 M I l @wil/@ @d S- Jan. il, 1938. F. R. NEE-LY COMPOSITE BOX AND MANUFACTURE THEREOF Filed Aug. l5, 1931 16 Sheets-Sheet 16 Patented Jan. 11, 1938 IE.l N T` 0 FF-l CE COMPOSITE' AB0X AAND IVIANUFACTURE THEREOF FrankRcdgeis'Neely;-Allentcwn, Pa., assigner to. A.. H. Balliet Corporation, Allentown, Pa., a corporation of Pennsylvania.

Application August 15, 1931, `Serial No. 557,340

4 Claims.- (Cl. 93-43)A My invention relates to composite boxes and tol the manufacture thereof.V

A purpose of `my invention is to cheapen and lessen the weight of boxes of a type hitherto usu7 ally made of wood -and in which the'lids can be nailed down.

A further purpose is to make the endseand bottom and permissibly the back of a box of corrugated paper or the like and part or all'of the "front of the box and the back, if desired, of wood composition orjthe like.

A further Ypurpose is to provide a box for easy manufacture on suitably modified existing ma- -'chines and that will have the appearance and other desired characteristics of Wooden boxes but be much lighter and cheaper than wooden boxes.

A further purpose is to make a composite box with inner and outer shells and both shells having ends higher than the sides.

A further purpose is to use extensions from the end flap of a blank for an outer shell as stays to hold together the set-up ends and sides of the shell.

A further purpose is to"cover the ends of drop lid ends of aninner shell with side turn-in portions of the end flaps of an outer shell.

A further purpose is to use a Wrapping machine to apply simultaneously an outer to an in ner shell` and an outside wrap to the outer shell.

A further purpose is to provide novel and desirable blanks for the manufacture ofY inner and outer shells of a composite box on a box machine.

A. further purpose is to provide a desirable method Voi manufacturing an inner box using a suitably modified existing machine.

A further purpose is to provide a desirable method of assembling inner and outer shells andV an external wrap.`

Further. purposes will appear in the specifica- 40 tion and in the claims.

I have elected to show a few only of the many forms of my invention, selecting forms that are practicalandelicient in operationand which well illustrateV the principles involved` Figure 1 is a perspective view showing finished box structure embodying my invention, the View being intended to represent equallywell `differ-` Figures 3a and 3b are fragmentary detailsections taken in positions corresponding to that of linef3-'3`of` Figure 1 with the alternative constructions respectivelyof Figures 2a and 2b.

Figures 4a and 4b are fragmentary horizontal sections taken in positions corresponding tothat of line yll-ll of Figure 1 with the alternative constructionsrrespectively of Figures 2a and- 2b.

Figure 5 lis a perspective View -comparing desirable forms .of inner and outer shells and wrap of the box of Figures l, 2a, 3a, and 4a, preparatory Yto assembly for feeding to a box machine and-iny position for assembly.

Figure 6 is a View generallysimilarto Figure 5 but different with respect to detail membersthe outer. shell and wrap. l

Figure 7 is a plan view of a desirable form of blank for the outer shell member of Figure 5.'

Figure 8 is a view corresponding generally with that of Figure 'l of a desirable form of the blank for the outer shell of Figure 6.

Figure 9 is :an end elevation of Figure 8.

Figure 10 is a plan View showing an inner shell assembled with an outer shell of the form of Figures# and 5, the view not including the outside Wrap, usually. applied to the structure of Figure 10.

Figure 11 isa front elevation of Figure 10. Figure 121s a top plan view corresponding generally to Figure 10 but showing the inner shell assembled with an outer shell of the form of Figures 6 and 8.-

Figure 13 is a vertical section upon the line v l3-l3 of Figure 12.

Figure 14 shows an inner box wrapped without an intermediate outer shell, the View being a top plan.

Figure 15 Ais a vertical section taken uponthe line Iii-2,15 of Figure 14. Y

Figures 16 to 18 inclusive are front elevations and Figs. -19 .toV 21 inclusive the corresponding plan views, allfsomewhat diagrammatic, illustrating successive early phases of the assembly of the inner shellwith the outer shell and wrap using la type of'wrapping machine disclosed in Kleinsmith et al., U. St Patent No. 1,733,229, with the machine somewhat modified to adapt it to the present method of manufacture, the form of outer shell lbeing that illustrated in Figures 5 and 7.

Figure 22 is a top plan view of one form of innerbox.

Figure 23 isa front elevation of Figure 22.

Figure 24 is an enlarged fragment of Figure22.

Figure 25 is a View corresponding to Figure 24 modied ,with respect to a minordetail.

Figure 26is a top plan View of one form of blank for the botto-m, ends and back of the inner box.

, Figure 27 is a plan View of a detail assembled with the blank or Figure 26.

Figures 28 and 29 are end elevations of Figures 26 and 27, respectively.

Figures 30 to 33 are views corresponding respectively to Figures 26 to 29 but showing the blank for bottom, ends and back in a slightly different form.

Figure 34 is a plan view of a somewhat different form oi inner box blank including separated portions for assembly in the box machine.

Figure 35 is a vertical section through the folded inner box made from the blank of Figure 34.

Figure 36 is a view corresponding generally to Figure 34 but showing a diierent form.

Figure 37 is a iront elevation of the set-upbox made from the form oi Figure 36.

Figure 38 is a top plan view of an inner box, the view corresponding generally to Figure 22 but showing a somewhat different form.

Figure 39 is a vertical section taken upon the line 39--35 of Figure 38.

Figure 40 is a fragmentary view corresponding to a modified portion of Figure 2 of U. S. Patent 1,383,697 to C. C. Davis, showing blanks for an inner box in a box machine preparatory to aS'- sembly.

Figure Lll is a fragmentary section corresponding generally to Figure 3 of the above patent, showing a number of set-up boxes, with thebottom box ready for downward discharge.

Like numerals refer to like parts in all figures. Describing in illustration and not in limitation and referring to the drawings:

The present invention is directed to what might be called a substitute box in that it comprises a wrapped box of a type that has heretofore been usually made or wood or the like, optionally looking like the wooden boxes of the prior art, having drop lid ends and a front adapted to hold one or more nails from the lid so that the box lid may be nailed down; also permissibly a back of different materials from the bottom and ends. The front and back may be made of wood or composition of which one example is found in chestnut board.

I-Ieretofore substitute boxes have been Without provisions for permitting an effective nailing down of the lids and in mgany cases, particularly when the boxes were intended to be used for cigars, this has been a feature so disadvantageous as to prevent the boxes frornbeing used for the intended purpose.

One of 'the wide applications for boxes of the present invention is thought to be for cigars or the like, with the boxes adapted to be closed, sealed and fastened shut by an inspector driving one or more nails at the forward edge of the lid downward into the front of the box.

Figure l shows a typical nished box of the present invention that is intended to have the outside appearance of a box of the prior art, for example that of a wooden cigar box.

The ends 55 are higher at 5l than the front and back sides 52 and 53 and the lid 54, shown in dot-and-dash, ts between the drop lid ends 5 I.

The box may comprise form A including inner and outer shells 55 and 56 and an outside wrap 51, as illustrated in Figures 2a, 3a, and 4a, or form B including an inner shell 55 and outer wrap 51 omitting the outer shell 56, as in Figures 2b, 3b and 4b, or form C which is form A modified with respect to a detail that is illustrated in alternative forms in Figures 2a and 2c.

In both the A and B forms the inner shell comprises a bottom 58, ends 59 and t5 and. permissibly a back 6I that are of corrugated board vor the like, preferably integral portions of a single piece, and a front 52 adapted to receive and hold a nail 54 from the outer edge of the lid 55, and the box covered by the Wrap 5'? will usually receive an inner lining of which a fragment as shown at 53 in Figure 2b, such for example as now applied to cigar boxes of the prior art but which I have not considered it necessary to show in more than this one gure.

Desirably the inner and outer shells are in registry or even with one'another along their corresponding upper edges, each shell including drop lid ends at 5l suitably higher than the top edges of the long sides at front and back.

The inner shell, exclusive of any stays, thus desirably includes larger and smaller board portions of'which the larger preferably comprises an inexpensive open texture composition board and the smaller one or more boards, one of sulicently dense texture to adapt the upwardly presented. edges to receive and hold one or more nails from the lid, and permissibly one capable of holding the lid.

The larger open texture board may usually include the bottom and ends of the inner1 shell, usually also, but not necessarily, the back of the shell and optionally also the shell front except at any part or parts thereof needing to receive and hold a nail or nails from the lid.

The smaller denser texture board includes an upwardly directed edge portion presented to the lid for nailing at any desired point or points thereof.

With boxes having a hinged lid the denser board `may include the whole or a portion only or" the shell front (Figures 2a, 22, 2c, 34, 35 and 37), or if preferred, the denser portion may also include the whole or a suitable portion of the shell back (Figures 38 and 39).

While an important feature of the invention is directed to means permitting anY effective nailing down of the lid, it will be understood that other features of the invention are independent of whether or not the lid is to be fastened down by one or more nails and, if ther'e'is to be no nailing, the open structure board may include both the front and the back as well as the ends and bottom of the shell.

The open board comprising the larger portion of the inner shell is suitably corrugated board, which may be lmade wholly or partially of chip board, kraft liners, straw board, chestnut board or other pulp board, paper or composition, herein called conventionally corrugated board and the portion presented to the nail or nails of the lid or which holds the back may be suitably wood or any composition board material, artificial or natural, adapted to receive and hold nails, such material being herein called conventionally dense board.

It will be Vunderstood, that while the lids of cigar boxes and the like adapted to be replaced by the substitute boxes of the present invention are in usual present practice wood, they may be of any suitable board, with or without wrapping.

Usually the inner box is made of board relatively thick as compared to the outer shell, the thinness of the outer shell insuring cleaner-cut outside corners along scored lines of the outer shell blank.

Cil

The Vouter shell is suitably .made of chestnut board, kraft liners or jute liners, kraft liners being particularly suitable. Y

The composite box may be lined before or after assembly. While illustrated as for lining subsequent to assembly in any suitable or usual way, it will be understood the lining may be applied to the inside parts of the inner box blank preparatory to setting it up into a box, thedense board front being separately lined.

The assembly of the inner box with the outer shell and wrap to provide a composite box of the form A, Figures l, 2a, 3a, and 4a, is illustrated for one form of outer shell in Figure 5 and also in Figures 16 to 21 and for another form of outer shell in Figure 6.

While in Figures 5 and 6 the inner box 55 is illustrated as externally stayed at the corners at 54 it should be understood that the showing of the inner box in these gures is intended for a conventional showing of any suitably set-up inner shell.

The blank 55 for the outer shell of Figure 5 and of Figures 16 to 2l is of novel cruciform, as best seen in Figure 7.

' it includes a body 65 that makes the bottom of the outer shell7 end flaps 5S and front and back flaps 6l, with score lines 68 and 69 between the body and the end and side flaps respectively.

The end flaps 66 make the ends of the outer shell and also short portions of the adjacent sides, having side turn-in extensions l0 from score lines l I, and the long side aps 6l may be preferably out away at the 'ends to clear in set-up positions the turn-in extensions 'l0 of the end flaps.

The side turn-in extensions 'i0 of the end flaps when set up function as stays and also as effective covers over the ends of the drop lid end portions of the inner box.

The side flaps 6l when set up preferably substantially ll the portion of the sides not covered by the side turn-in extensions lli of the end flaps 56, with edges 'i2 and 13 respectively or" the side flaps and end flaps relatively substantially perpendicular whatever the selected angles of these edges with the long side score line 59.

Referring to Figure 5, a wrap 5l, outer shell blank 55 and set-up inner shell 55 are illustrated as having been delivered one above another for easy registered assembly.

The wrap 51 may comprise any appropriate wrap of the prior art and may be delivered, glueside up, from any glue machine.

The outer box blank 5S registered vertically above the wrap may be received from a stencil gluer, with the upper side stencil glued as along the edges and at intermediate strips.

The inner shell 55 comprises any type of box, preferably having a front 52 adapted to receive one or more nails from the lid and the remainder ci the box is made of any inexpensive board, which may be corrugated board. They are delivered set-up exteriorly unglued and registered above the outer box blank 56.

The portions 16, 65 and 58 respectively of the wrap 57, blank 56 and inner box 55 that are to form the bottom of the composite box are regV4 Istered together.

The bottom portion 65 of the open blank 56 of the outer shell may be registered upon the glued surface 'i6 of the wrap, and the inner box 55 is then registered upon the stencil-glued upper surface of the blank 56.

The inner box 55 carrying the 'blank 56 for the outer shell upon its bottom and the wrap 51 upon the bottom of the blank 56 may then be assembled into the finished box, either by hand operation, or better, by the use of any one of a number of dilerent wrapping machines of the prior art, modied as to minor details.

One such machine has been disclosed and claimed in U. S. Patent No. 1,733,229 to Kleinsmith et al. In order that the assemblage of the parts may be understood, I have illustrated parts of the assemblage with reference to a machine of this general character in Figures 16 to 2l.

The inner box 55 and the adhering blank 55 and wrap 5l are pushed upwardy to place upon a form 7'! of a wrapping machine, the form Tl being, for example, the split form of the Kleinsmith patent provided with end clips 18 also of the prior art.

The end ilaps 66 of the outer shell are clipped at 'i8 in set-up positions against the ends of the inner shell. 'Ihe assembled members may be placed upon the form VI while the form is in its normal raised position, that at which the form would receive a box for wrapping in the usual Way.

When the end flaps of the outer shell include the side turn-in extensions lll, structure should be added to the wrapping machine for automatically turning these extensions on to the sides of the inner shell preparatory to the setting up of the long side flaps 6l'.

As illustrated, rocker members 'I9 having stationary horizontal pivots 85 are angularly positioned by the mechanism of the box machine to effect the turning of the extensions '10.

The levers 'I9 are maintained raised as in Figures 16 and 19 during the application of the assembled inner and outer shells and wrap to the form T! at which time the inner shell already set up is fitted upwardly on the form and the end iiaps B5 of the outer shell set up against the ends of the inner shell are inserted under the clip members 7B of the form.

After applying the assembled shells and wrap to the form, the iirst operation of the machine may include a concurrent downward movement of the form and an angular downward turning of the members 'i9 about their pivots 8B. Sprin ears or plates 8l at the ends of cross portions 62 of the levers 1S sweep in the end extensions I0 upon the long sides of the inner shell. The levers 'i9 then come to rest, as at the position of Figures 1'7 and 20, with the spring ears 8l holding the extensions ED in their set-up positions, preferably before and during an early portion of the upward turning of the long side naps 61.

The form 'il moves downwardly from the position of Figures 17 and 20 between the usual long side turn-up rolls 83, coming to rest after having moved downwardly somewhat beyond the position indicated in Figures 18 and 21.

During this downward movement of the form the long side naps 85 of the wrap and corresponding naps 67 of the outer shell are swept up simultaneously, the turned-over extensions 10 of the outer shell receiving the registering portions oi" the outer wrap as it travels downwardly from the holding turn-in ears Si.

When the form comes to rest the long side flaps project beyond the top and ends of inner and outer shells, as in the usual wrapping of a box.

The turn-in arms 'l5 may retract in any way to their horizontal positions of Figures 16 and 19 as soon as they have released the turn-in extensions 'I0 by reason of the downward travel of the form.

The next operation, the turning in of the end turn-ins 85 of the long side ilap of the wrap, and the succeeding operations may be optionally as described in the Kleinsmith patent and are therefore not described here.

It will be seen that the only substantial change in the mechanism oi theA prior art includes the mechanism for turning in the side turn-in flaps 'lil of the end flaps of the outer shell.

The new mechanism functions before the usual folding mechanism of the box machine, all of which may optionally be that of any box machine, the usual mechanism thus simultaneously setting up the iiaps of the outer shell and of the wrap.

While it is desirable to apply the wrap and outer shell simultaneously to the box this is not essential and the inner shell and outer shell may be combined without an outer wrap. This is sometimes worthwhile in that the different box manufacturers do not all use the same wraps.

The inner shell may also be wrapped without the outer shell, as shown in Figures le and 15.

Figures 10 and 11 illustrate this type of box. It will be seen, Figure il, that the side turn-in extensions lll from the end flaps oi the outer shell Very effectively cover the end portions of the drop lid ends of the inner shell and also serve as stays for holding the outer shell to the inner shell.

Figure 6 shows the assembly when the outer shell is set up from a conventional cruciform blank.

In this event the cruciiorm wrap is preferably provided with upwardly glued corner stays at 8b as by mechanism of the prior art, for example by means of a Stokes & Smith gluing machine with a tabbing attachment which ts the four corner stays on to the wrap in glued condition. Such a machine is described in Letters Patent No. 1,806,181, issued to E. G. Rider.

As before the top of the wrap is glued. The cruciform blank t for the outer shell, stencil glued on its upper side, is registered upon the wrap 5l and the unglued inner shell 55 is registered on top of the outer shell 56.

It will be understood that the cruciform outer box, in flat condition, may be stencil glued on its upper side in an ordinary stencil gluing machine, after which it may be spotted or registered on the upper glued race o1 the wrap and on top of the stays 8E which may suitably comprise kraft paper tape of the prior art. The inner box is next placed upon the ilat stencil-glued outer box wrap and the three assembled members applied to the form of a wrapping machine which may include the clip mechanism ior holding the end flaps to position but obviously need not include the side turn-in mechanism already described. The nished box is oi the form shown in Figure 2o already described as is also the form having side turn-in aps across the ends of turn-in ends oi the inner box.

As before the outer box may be applied to the inner box without the wrap as illustrated in Figures 12 and 13.

It will be seen that the stays 35 at the corners, unnecessary in the form shown in Figures and 11, make the composite box sufliciently rigid for the intended purpose, particularly after wrapping, which latter may be accomplished exactly as in the wrapping oi an ordinary box of the prior art.

The inner box may be wrapped without the application of the outer shell, the desirability of the outer shell depending, to considerable extent, upon the intended use of the box and also upon the construction of the inner box.

When the outer shell is to be omitted it will usually be best to strengthen the connection between the front portion or the inner box and the board portion unless the duty is to be quite light.

Figures 22 and 23 show an inner box set up from a blank shown in Figure 25 and whose front is shown in Figure 27. The hat box blank includes a bottom 8l, the ends t8 and the back te, the front Q0 being adapted to seat upon the bottom between the ends 88 when these are turned Normally the end ilaps 83 are stayed on the outside to the sides by suitable kraft tape or the like as indicated at $4.

1f the inner box is to receive an outer shell, the stay fastening between the bottom 8l of the box and iront Si) may be omitted in that the outer shell will maintain the parts in their proper relative positions. Optionally however the bottoni may be fastened to the iront as by nailing or by staying.

Usually inner staying is not necessary, the corner staying being as illustrated at ts, Figure 24.

Where a particularly strong construction is desired, an inner stay may be added as indicated at 9i, Figure 25.

rlfhe score lines where the flaps turn up in the corners may be crushed, as indicated in Figures 25 and 28 at 92 or skived .as indicated at S2', Figures 30 and 32.

While it is usually more desirable to malte the front or back as a singie unit adapted to take nails or to hold the lid at any point along its length, it will be understo-od that surface may be provided merely at the point or points that are to receive the nail or nails.

In Figures 34 and 35 a portion '23 of t. flap is made integral with the bottom or the and therefore with the ends and back. A r tively narrow strip or dense board, suitably wood, is provided at Sil above the lower portion of the front.

In Figures 34 and 35 the wooden strip extends the length of the front. As in many cases the iront has to hold but a single nail, the dense board portion may include an insert at the receiving point of the front, as indicated at 95 in Figures 36 and 37. More usually, the composite portion of the inner box will include the bottom, ends and back only, set-up about suitable crushed or skived score lines and assembled with a wood front.

In some circumstances it may be preferable to make both front and rear sides of dense board. This is particularly desirable for boxes that have unhinged lids, as both sides'oi the lids may then be nailed to sides intermediate the'drop lid ends, or when particularly rigid boxes are desired.

The setting up o the inner shell may be made in any suitable way, and is perhaps most conveniently made on a modiiied quadruple staying machine, such for example as that described in U. S. Patents 728,806 and 1,383,697. The corrugated sheets are cut to size on any suitable cutting machine, then scored along the folding lines, as by skiving or crushing. The corners are then cut out as by means or' a box corner cutter on a 90 angle.

In setting up, assuming the mechanism of the quadruple staying machine described in the above 

